Indexable Cutting Insert Geometry for Ramping and Finish Milling
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Solution Overview
Problem
Existing indexable insert milling cutters cannot perform ramping operations due to the absence of a ramping cutting edge and suffer from instability and limited tool angles, affecting cutting performance and accuracy.
Innovation Solution
A vertical cutting edge double-sided cutting insert with a minor cutting edge configuration that includes a first minor cutting edge for finish operations and a second minor cutting edge for ramping operations, along with optimized flank face angles to enhance stability and tool angles, allowing for face milling, shoulder milling, and pocket hole digging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the minor cutting edge is configured as only a flat cutting edge, then the finish operation capability is improved, but the ramping operation capability deteriorates
Solution Approach 1:
The minor cutting edge is divided into two distinct segments: a first minor cutting edge for finish operations and a second minor cutting edge for ramping operations. This segmentation allows each cutting edge to be optimized for its specific function, resolving the contradiction between finish operation capability and ramping operation capability
Solution Approach 2:
The cutting insert is designed with multiple cutting edges that provide multi-functionality. The first minor cutting edge handles finish operations while the second minor cutting edge handles ramping operations, enabling the same insert to perform multiple different operations without requiring tool changes
2Ease of operation
If the contact area between the cutting insert and insert mounting seat is insufficient, then the mounting simplicity is improved, but the mounting stability deteriorates
Solution Approach 1:
The cutting insert employs different face configurations at different locations: the first and second faces are formed in one plane to provide stability during mounting, while the third face is formed in a different plane to enable proper seating and contact with the mounting seat, achieving both simplicity and stability
3Ease of manufacture
If the tool angle of the minor cutting edge is limited, then the ease of manufacture is improved, but the cutting performance deteriorates
Solution Approach 1:
The cutting insert utilizes asymmetric face arrangements where the third face is formed in a different plane from the first and second faces. This asymmetric configuration enables the minor cutting edges to achieve larger tool angles and improved clearance angles without complicating the manufacturing process
Data Source
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AI summary
A minor cutting edge 15 has a first minor cutting edge 31 and a second minor cutting edge 32 that extends inward of the insert in a direction of an insert short side face axial line C3, as the second minor cutting edge 32 extends from the first minor cutting edge 31 in a direction of an insert major face axial line C1. A flank face 42 of the second minor cutting edge 32 is inclined outward of the insert in the direction of the insert short side face axial line C3, as the flank face 42 extends from the second minor cutting edge 32 in the direction of an insert long side face axial line C2, and is inclined outward of the insert in the direction of the insert short side face axial line C3, as the flank face 42 extends from a major face 11 adjacent to the flank face 42 in the direction of the insert major face axial line C1. A length of a flank face 41 of the first minor cutting edge 31 is shortened in the direction of the insert major face axial line C1, as the flank face 41 extends from the first minor cutting edge 31 in the direction of the insert long side face axial line C2. The flank faces 41 of a pair of the first minor cutting edges 31 of a short side face 13 are formed in mutually different planes.